Cpb Brochure Diaphragms en 2

8/9/2019 Cpb Brochure Diaphragms en 2

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Mill Diaphragms


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Innovations fromChristian Pfeiffer:

giving you the lead.

Improving industrial grinding pro-

cesses with pioneering innovations

has been Christian Pfeiffers mis-

sion since its foundation in 1925.

Our companys unique develop-

ments include

the adjustable diaphragm

separator technology for

cement grinding.

From the research and develop-

ment stage to production and in-

stallation, as an industry pioneer

we have the advantage of decades

of experience. We draw on cutting-

edge knowledge and new findings

gained through close cooperation

with customers, research insti-

tutes and universities.

To optimally supply our interna-

tional customers, we oper-

ate production facili-

ties around the world

including one in

China. Our plants

all adhere to the

same high qual-

ity standards for

which Germany isrenowned.

Innovation and R&D


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Greater efficiency:all in the diaphragm.

By reducing energy consumption

and increasing efficiency, the

diaphragm is crucial to the profit-

ability of your system. It is the

diaphragm that regulates the

material filling level and the heat

exchange in the compartments.

The more intelligent the design,

the more economically efficient

the energy-intensive processes

within your mill.

Mill diaphragm

Installing a Pfeiffer-Monobloc guarantees many years of high grinding

plant availability and continuous finish material quality.

Adjustable material ow

control system, fully opened

(left), fully closed (right)


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The Monobloc:globally unique.

The sturdy Monobloc is making

industry history. With its extreme-

ly long service life, this diaphragm

has proven itself to be the most

sophisticated solution for modern

ball mills for many decades.

Its design is the only one of itskind in the world and is unbeaten

in stability. Comprising a self-sup-

porting U-ring for axial fixation

on the mill tube, it supports

the mill cylinder and

prevents deforma-

tions.

Another special

feature is the

oating xationof the intermedi-

ate diaphragms,

guaranteeing

stress-free fastening

to the mill shells.

No other mill diaphragm offers

such outstanding qualities as the

Monobloc often imitated, never

matched.

Stability and reliability of mill tube using

different intermediate diaphragm designs

Monobloc

Christian Pfeiffer Monobloc

Conventional diaphragm design

Christian Pfeiffer Monobloc


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Slotted plates:unrivalled dimensional

stability.

Your plants profitability will also

increase with the specially devel-

oped diaphragm plates from Chris-

tian Pfeiffer. The optimised design

includes innovative plate slots with

a small conical enlargement, en-

suring that the material is only for-

warded once it has been ground to

a suffi cient degree. Constant condi-

tions for material transfer are thus

guaranteed throughout the service

life and the plates do not clog!

Slotted plates from Christian

Pfeiffer are made from specially

treated, breakage resistant rolled

steel which is tempered up to 60

HRC. This process guarantees con-

sistent hardness across the entire

slotted plate, producing an excel-

lent material with an extremely

long lifetime.

An equally unique development is

the innovative fastening system

designed by our engineers. Bolts

with conical swages combined with

the special slotted plates from

Christian Pfeiffer allow effi cient

plate use up to a residual thicknessof 8 mm. Thanks to this design, we

can achieve a utilisation level of

75 % compared to conventional

systems, which only manage 60 %

(20 mm).

Fastening System

Slotted plates

Wear

plate

Hexagonal bolt Tear-off bolt

Diaphragm

structure

Wear zone

20 mm

Wear zone

8 mm

Cast plates CPB rolled steel plates

50 HRC 60 HRC

Conical slot shape and plate hardness


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Separate outlet:ground material below,

air at the top.

Conventional mill diaphragms

send most of the material through

the air ow into the second grind-

ing compartment in an

uncontrolled manner. The results

are energy loss and a high degree

of wear on the grinding media and

diaphragm plates. Large areas of

both compartments are left with-

out grinding material.

Mill diaphragms from Christian

Pfeiffer are the intelligent solution

to this problem. In the first grind-

ing compartment, the material

level is kept constant thanks to an

innitely adjustable ring, which

can be directly accessed and in-

dividually adjusted. In the second

grinding compartment, the

material falls down through sepa-

rate openings underneath the

air ow, along the diaphragm and

directly into the ball charge.

Air flow

Air velocity through ball mill

Optimized CPB-DesignConventional design

Material ow through intermediate diaphragm

10 m/s 20 m/s


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Increased air passage:improved cooling,

shorter retention times.

Our engineers have succeeded in

increasing the air passage sur-

face of the diaphragm without

compromising on stability. The re-

sult is 40% lower pressure loss

compared to conventional dia-

phragms.

This ingenuous design offers nu-

merous benefits through better

cooling of your grinding material,

more effective fines discharge and

shorter retention times without

the risk of overgrinding.

Minimal pressure loss

[m/s]

0.007.7615.5323.3013.06

Calculated air velocity above ball charge

v = 1.8 m/s v = 1.8 m/s


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Mechanical design and service life: Comparison ofconventional design to Christian Pfeiffer Monobloc

Basis: Closed circuit, ordinary cement production without pre-grinding system

Conventional design Christian Pfeiffer Monobloc

Structure Cast segments & individual-

ly bolted with a typical ser-

vicel life of 5 years

Welded free-standing steel

structure with servicel life in

excess of 10 years

Slotted plates

Material Cast Machined & heat-treated

special alloyed rolled steel

Hardness 42 - 48 HRC 52 - 59 HRC

Thickness 50 - 60 mm 40 - 70 mm

Slot width 10 - 15 mm 4 - 6 mm

Service life 5,000 - 7,000 hours

8 - 18 months

15,000 - 20,000 hours

> 36 months

Slot shape Peening over Constant

Material level No control Adjustable

Ventilation Restricted (higher p) Maximized (lower p)

Longer service life

Structure

Wear plates

1 x

1 x

2 x

2-4 x


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Precision engineering &process know-how: Basis

for design & fabrication

Our engineers primary goal is to

increase efficiency. Nowadays,

their comprehensive knowledge of

all details about the grinding pro-

cess leads to a significant increase

in production of many grinding

plants but with a reduced power

consumption.

Moreover, reliability is enhanced,

non-operation periods are kept to

a minimum and repair and main-

tenance costs are reduced.

Price

Useful life

Repairs

Maintenance

Carbon footprint

Quality

Energy

Efficiency

TCO Total Cost of Ownership

Total Cost of Ownership


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Our experts:specialists in all areas.

Since its early beginnings, our

company has been inuencing the

industrial grinding of cement.

Our engineers and design experts

can accordingly draw on an exten-

sive wealth of experience and

accumulated knowledge. State-of-

the art technology is also usedroutinely in our work.

For complete planning reliabili-

ty: all production processes are

CAD/CAM controlled.

For high precision: CNC machines

provide exact customization.

For long service life:

forces are structurally andmathematically simulat-

ed using the FEM

(Finite Element

Method).

Engineering


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Controlled quality:in-house production.

For all of our supplies and ser-

vices, our companys policy has

always been to implement and

strictly comply with our own high

quality standards as well as

national and international quality

standards and guidelines such as

DIN EN ISO 9001.

All product range components

that are directly relevant for

grinding and separation are

entirely manufactured by our own

production facilities. Theres a

good reason why we never pro-

cure parts from other manufac-

turers: we want to keep on provid-

ing you with a controlled level

of consistently high quality.

Production


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= Offices/Production facilities

= Agents/Representations

Christian Pfeiffer worldwide

Christian Pfeiffer Maschinenfabrik GmbH

Sudhoferweg 110-112 59269 Beckum, Germany

Phone: +49 2521 849-00 Fax: +49 2521 849-123

Email: [email protected]

www.christianpfeiffer.net

Documents

Cpb Brochure Diaphragms en 2